Just a quick Instructable on this waterproof mint tin stereo I recently built. I won't go too in-depth with the whole wiring process and everything, but if you check out my Altoids tin speaker Instructable there's a detailed schematic there. This is meant more just as a basic guide more than anything else.
I've embedded a quick demo video to prove that it still works while being drenched with water!
-Tin (I used a Ricola lozenge tin)
-LED bezel (optional)
-3.5mm female panel mount jack
-Switch (the amp I used had a built in switch)
-Waterproof speakers x2
-Rubber washers to go around speakers x2
-A cap from a pen
-Small rubber washer to go around pen cap
-Drill with various sized bits
-Soldering iron and solder
-Heat shrink tube or electrical tape
-Hot glue gun
Let's get started!
Step 1: Prepare Tin
First thing you need to do is make some holes in your tin for your speakers, 3.5mm jack, LED, and switch. To make the holes in the top for the speakers, it's easiest to use a hole saw, but I didn't have one handy so I used a knife and file. Since the metal is very thin, I used a box cutting knife to cut a rough outline of the size of the speakers and then went around the outside of the holes with a round file just to smooth it out.
The other holes are easy since they can be drilled with standard sized drill bits.
Step 2: Attach Speakers
Now, put your speakers in the holes you just made and seal them well. To do this, I put a rubber plumbing washer around each speaker on the outside of the tin and then sealed all the way around both speakers with epoxy glue on the outside of the tin. Then, I ran a generous bead of hot glue around the inside of the tin surrounding the speakers to ensure a watertight seal.
Step 3: Attach Other Components
Now you need to attach your amp, battery holder, LED, switch and 3.5mm jack. I sealed all of these off with a very generous application of epoxy glue to ensure a watertight seal. Depending on your exact tin and components, your placement will most likely vary from mine.
Step 4: Solder
Now you need to solder everything together.
Solder the L, R, and GND wires from your 3.5mm jack to the input of your amplifier. Then, solder the positive and negative wires from your two speakers to the positive and negative outputs of your amplifier. Next solder your battery holder positive and negative terminals to the power of your amplifier with your switch in series and your LED in parallel. My amp had a built in switch, so I didn't need a separate switch, but I had to tap into my built in switch to wire the LED up.
Step 5: Test the Seal
Before you put batteries in it and hook up an audio source, make sure you test your tin to make absolutely certain in it waterproof! To do this, I held mine under a tap for around 30 seconds, the dried it off on the outside and then opened it up and carefully inspected the inside to make sure no water had gotten in. This is very important!
Step 6: Install Batteries and Test It Out
Now, put your batteries in, hook up an audio source and test it! To seal the 3.5mm jack and protect it from water, I made a little waterproof cover. I made the cover by cutting a piece off of a pen cap and glueing a small rubber washer it it (see pic). If all goes well, you've got a cheap little waterproof stereo! Keep in mind, it's more water resistant than waterproof. I wouldn't recommend submersing it in water or anything.
I hope you enjoyed this quick little Instructable!